Universal End Clamp

ABSTRACT

A clamp has a body, a wedged channel nut, and a bolt. The body has a first component extending from the body and configured to engage a module and a second component having a tapered body surface. The wedged channel nut has a first flange and a second flange extending from opposing sides of the nut and configured to engage a rail and a tapered nut surface having an angle substantially identical to the angle of the tapered body surface of the second component, wherein the tapered nut surface engages the tapered body surface. A bolt extends through the wedged channel nut and the body. When the bolt is tightened, the nut and the body secure the module and rail together.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional application of U.S. application Ser.No. 12/470,682, entitled “Universal End Claim,” filed May 22, 2009,which claims priority to U.S. Provisional Patent Application Ser. No.61/071,891, entitled “Device and Method for Solar Panel Installation,”filed May 22, 2008, which are hereby incorporated by reference in theirentirety. This application is related to U.S. patent application Ser.No. 12/470,697, entitled “Module Attachment Apparatus and Method,” filedMay 22, 2009, and U.S. patent application Ser. No. 12/470,588, entitled“Camming Clamp for Roof Seam,” filed May 22, 2009.

FIELD OF THE INVENTION

The invention relates generally to a clamp for securing a solar moduleor other component to a rail.

BACKGROUND

Solar energy generation is a rapidly growing technology worldwide andoffers the potential of almost unlimited clean and sustainable energy.However, the use of solar electric technology has been limited by thecosts associated with installing solar panels to existing and newstructures and facilities.

When installing a solar module on a rail, various clamps must beutilized due to the varying sizes of the modules and various railconfigurations. As a result, it is desirable to have a clamp that can beused to secure different types of modules to different types of rails.

The solar module is often installed on a roof or other surface forexposure to sunlight. As a result, the installed solar module can beviewed. Accordingly, it is desirable to have a clamp that isaesthetically pleasing and is preferably hidden under the module frames.

Because maintenance may be required for the solar modules and becausethe solar modules may be installed on a roof or other surface whereaccess is often needed, safety is also an important consideration.Modules can be installed at a variety of heights, commonly about threeto eight feet off the ground, and on a variety of surfaces, such as aroof of a building. When someone is walking next to a solar module, itis desirable that the rail does not extend past the edge of the module.

SUMMARY OF THE INVENTION

Various embodiments described herein attempt to overcome the drawbacksof the conventional techniques and devices for solar cell arrayinstallation.

The systems, methods, and devices described herein can offer, amongother advantages, decreased cost of installing solar cell arrays orcomponents thereof. This can be accomplished in an efficient and robustmanner compared with the current installation techniques and devices.The systems, methods, and devices can be installed without drillingcomponents during installation. Also, the modular nature can allow foreasier installation and breakdown.

In one embodiment, a clamp comprises a body, a wedged channel nut, and abolt. The body has a first component extending from the body andconfigured to engage a module and a second component having a taperedbody surface. The wedged channel nut has a first flange and a secondflange extending from opposing sides of the nut and configured to engagea rail and a tapered nut surface having an angle substantially identicalto the angle of the tapered body surface of the second component,wherein the tapered nut surface engages the tapered body surface. A boltextends through the wedged channel nut and the body. When the bolt istightened, the nut and the body secure the module and rail together.

In another embodiment, a system comprises a module, a rail configured tosupport a module; and a clamp. The clamp includes a body including afirst component extending from the body and configured to engage asurface of the module; and a second component having a tapered bodysurface. The clamp also includes a nut including a first flange and asecond flange extending from opposing sides of the nut and configured toengage opposing sides of the rail; and a tapered nut surface having anangle substantially identical to the angle of the tapered body surfaceof the second component, wherein the tapered nut surface engages thetapered body surface. A bolt extends through the nut and the body. Whenthe bolt is tightened, the nut and the body secure the module and railtogether.

In yet another embodiment, a clamp comprises a body, a nut, and a bolt.The body includes a first component extending from the body andconfigured to engage a module; a second component extending from thebody and configured to engage a first slot in a rail; and a thirdcomponent having a tapered body surface. The nut includes a tapered nutsurface having an angle substantially identical to the angle of thetapered body surface of the third component, wherein the tapered nutsurface engages the tapered body surface; and a nut extension having anut flange configured to engage a second slot of the rail. A boltextends through the nut and the body. Tightening of the bolt causes thenut and the body to secure the module and rail together.

In another embodiment, a clamp comprises a bolt extending at least awidth of a module; a body having an aperture to receive the bolt and abody flange extending from the body toward the module; and a nut havinga nut aperture for receiving the bolt and a first nut flange and asecond nut flange extending from the module. Tightening of the boltcauses the nut and the body to secure the module and rail together,wherein the body flange is configured to pierce the module, and whereinthe first nut flange and the second nut flange are configured to piercethe rail. Piercing of the rail and module surface finishes can ensureelectrical and grounding conductivity between all of the associatedcomponents.

Additional features and advantages of an embodiment will be set forth inthe description which follows, and in part will be apparent from thedescription, or may be learned by practice of the invention. Theobjectives and other advantages of the invention will be realized andattained by the structure particularly pointed out in the exemplaryembodiments in the written description and claims hereof as well as theappended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the present invention are illustrated byway of example and not limited to the following figures:

FIG. 1 a shows a cross-sectional view of single bolt universal moduleend clamp in a first installation position according to an exemplaryembodiment.

FIG. 1 b shows a cross-sectional view of single bolt universal moduleend clamp in a second installation position according to an exemplaryembodiment.

FIG. 1 c shows a cross-sectional view of single bolt universal moduleend clamp in a third installation position according to an exemplaryembodiment.

FIG. 1 d shows an end view of single bolt universal module end clamp ina final installation position according to an exemplary embodiment.

FIG. 1 e shows an exploded view of a module end clamp according to anexemplary embodiment.

FIG. 1 f shows an assembled view of a module end clamp according to anexemplary embodiment.

FIG. 1 g shows an exploded view of an installed module end clampaccording to an exemplary embodiment.

FIG. 2 a shows a perspective view of a module end clamp in a firstinstallation position according to an exemplary embodiment.

FIG. 2 b shows a perspective view of a module end clamp in a secondinstallation position according to an exemplary embodiment.

FIG. 2 c shows a perspective view of a module end clamp in a thirdinstallation position according to an exemplary embodiment.

FIG. 2 d shows a perspective view of a module end clamp in an installedposition according to an exemplary embodiment.

FIG. 2 e shows a perspective view of a module end clamp in an installedposition according to an exemplary embodiment.

FIG. 3 a shows a cross-sectional view of a universal module end clampfor a side-slot style rail according to an exemplary embodiment.

FIG. 3 b shows a side view of a universal module end clamp for aside-slot style rail according to an exemplary embodiment.

FIG. 4 a shows a cross-sectional view of a grounding channel nut and midclamp securing two modules to a parallel rail according to an exemplaryembodiment.

FIG. 4 b shows a cross-sectional view of a grounding channel nut and midclamp securing two modules to a perpendicular rail according to anexemplary embodiment.

FIG. 4 c shows a cross-sectional view of a grounding channel nut and midclamp securing two modules to a perpendicular rail according to anexemplary embodiment.

DETAILED DESCRIPTION

Reference will now be made in detail to the preferred embodiments of thepresent invention, examples of which are illustrated in the accompanyingdrawings.

FIGS. 1 a to 1 d show an installation of a single bolt universal moduleend clamp 100 for securing a solar module 110 to a rail 120. FIGS. 1 eand 1 f show perspective views of the components of the module end clamp100. FIG. 1 g shows an exploded view of an installed module end clamp100. Although a solar module is described herein, it is intended toinclude any component of a solar cell array to be secured, including,but not limited to, a photovoltaic array, a photovoltaic module, a solarcell, a rail, a solar panel, a solar tracker, a mounting post or pole,and a mounting bracket. However, the term module is not intended to belimited to components used for solar energy and solar componentinstallation. The module can apply to any component that can be securedto a roof, including, but not limited to, a satellite dish, an antenna,and HVAC equipment. Also, although the clamp may be referred to as anend clamp, the clamp can be used at any location along a rail to securea module. Additionally, in some embodiments, the clamp may be configuredas a mid clamp.

The exemplary module 110 shown represents an end portion of the module110. The module 110 includes a frame 110 a that extends perpendicular toand supports a solar panel glass 110 b. On a distal end of the frame 110a opposite the solar panel glass 110 b, the frame 110 a includes aflange 110 c extending perpendicular to the frame 110 a in a directionbeneath the solar panel 110 b. The flange 110 c shown is merelyexemplary, but it is common for various configurations of modules toinclude a flange. The underside of flange 110 c is flat and isconfigured to abut a flat, upper surface of the rail 120. Although thisexemplary module is shown, it is intended that any configuration ofmodule can be used.

The rail 120 can be secured by a variety of means to a roof or othersurface for mounting the solar module for exposure. As shown in thecross-sectional view in FIG. 1 d, the rail 120 can be constructed of asingle material, such as anodized aluminum. In this exemplaryembodiment, the rail 120 has a first vertical component 120 a and asecond vertical component 120 b that are substantially connected by ahorizontal component 120 c to form a void 120 d that can receive theclamp 100. The first vertical component 120 a and the second verticalcomponent 120 b can be used to support the module 110 and abut or engagean installed wedged channel nut 140.

The end clamp 100 has an end clamp body 130, an end clamp wedged channelnut 140, and a torque bolt 150. The body 130 has a horizontal component130 a and a vertical component 130 b extending perpendicular to thehorizontal component 130 a. At a distal end of the horizontal component130 a, the body 130 has a flange 130 c extending downwardly andperpendicular from the horizontal component 130 a. The verticalcomponent 130 b extends into a nut-receiving component 130 d thatextends outwardly in a direction away from the horizontal component 130a. In a direction parallel to the horizontal component 130 a, thenut-receiving component 130 d tapers to a point 130 e.

The wedged channel nut 140 has a first surface 140 a that is flat andconfigured to abut a flat surface of the rail 120. The wedged channelnut has a second surface 140 b configured at an angle substantiallyidentical to the angle of the tapered nut-receiving component 130 d. Athird surface 140 c is perpendicular to the first surface 140 a and isconfigured so that it can abut a flat surface of the vertical component130 b. A fourth surface 140 d, which faces a direction away from thebody 130, is configured to receive the bolt 150 through an aperture 140e, shown in FIG. 1 d. The aperture 140 e is elongated and is configuredto allow movement of wedged channel nut 140 in a vertical directionwhile maintaining the position of the bolt 150.

The bolt 150 extends through the wedged channel nut 140 and into thebody 130. The body 130 has a threaded aperture for receiving a threadedcomponent 150 a of the bolt 150. The bolt 150 can engage or disengagethe wedged channel nut 140 and the body 130 by using torque to rotate apolygonal component 150 b at a distal end of the bolt 150. It isintended that the bolt 150 can have any configuration at the distal endthat allows a user to rotate the bolt or allows the bolt to engage ordisengage, such as a screwdriver receiving recess, and is not limited toa polygonal component, such as a hexagonal or pentagonal shapedcomponent. In this exemplary embodiment, when the bolt 150 is completelytightened, a distal end of the threaded component 150 a can extend pastthe nut-receiving component 130 d of the body 130.

As shown in FIG. 1 a, the module 110 can be secured to the rail 120 bylowering the module 110 onto the rail 120, whereby the clamp 100 doesnot obscure the alignment of the module 110 and the rail 120. The bolt150 and wedged channel nut 140 are in an initial position whereby thewedged channel nut is at a first position resting along nut receivingcomponent 130 d.

Referring to FIG. 1 b, the module 110 is aligned with the rail 120. Theclamp 100 can be guided such that the horizontal component 130 a andflange 130 c of the body 130 are positioned above the flange 110 c ofthe module 110. Additionally, the wedged nut channel 140 is positionedbeneath the rail 120 and substantially aligned with the flange 110 c.Once the clamp 100 is substantially in this position, the bolt 150 canbe tightened so that the wedged channel nut 140 engages the body 130 tosecure the module 110 to the rail 120.

FIG. 1 c shows a cross-sectional view of the module 110 and the rail 120having a substantially installed clamp 100. FIG. 1 d shows an end viewof the module 110 and rail 120 having an installed clamp 100. Torque isapplied to the bolt 150 causing the threaded component 150 b to engagethe aperture of the body 130 and extend beyond the aperture in the nutreceiving component 130 b. As the bolt 150 is rotated, the secondsurface 140 b of the wedged channel nut 140 slides along the nutreceiving component 130 d. As the wedged channel nut 140 slides alongthe nut receiving component 130 d, the module 110 and the rail 120 areheld together by a force pushing down by the flange 130 c of the body130 and a force pushing up from the wedged channel nut 140. Theseforces, which are maintained by the position of the bolt 150, cause theclamp 100 to lock the module 110 against the rail 120. The amount oftightening of the bolt 150 required to secure the module 110 to the rail120 can depend upon the thickness of the module 110 and the thickness ofthe rail 120.

As shown in FIGS. 1 d, 1 e, and 1 f, the wedged channel nut 140 has afirst flange 140 f and a second flange 140 g, each of which extend alonga side of the wedged channel nut 140 in a direction substantiallyparallel to the direction of the bolt 150. As the wedged channel nutengages the rail 120, the first flange 140 f and the second flange 140 gcan enter a recess in the rail 120 or be configured to puncture asurface of the rail 120. The first flange 140 f and the second flange140 g force the rail 120 in a direction towards the module 110.

By installing the clamp 100 on the module 110 and the rail 120, a solarcell array or components thereof can be secured together withoutdrilling into either component. By securing the rail 120 to a roof orother support surface, the module 110 can be supported and positionedwithout any damage to the module 110. Also, by reversing the processdescribed above, the clamp 100 can be uninstalled in a similar fashion.

FIG. 1 g shows an exploded view of the installed clamp 100 securing themodule 110 to the rail 120. Because the installed clamp 100 is set backslightly from an edge of the rail 120, a cap 160 can be installed on therail 120. The cap 160 can include a plurality of cap extensions 160 athat are inserted into the rail 120 to frictionally engage the rail 120.In one exemplary embodiment, the cap 160 can be made of rubber, thoughany known material to one of the art can be used. The installation ofthe cap 160 allows a flush end of the rail 120, which is safer thanexposing the sharp edges of the rail 120 and can be more aesthetic.

FIGS. 2 a to 2 e show a perspective view of an installation of a clampis shown according to another exemplary embodiment. As shown in FIG. 2a, a clamp 200 can be slid into an end of a channel in a rail 210 suchthat a head of a bolt 200 a remains exposed to an installer. A clampbody 200 b and a wedged channel nut 200 c of the clamp 200 areconfigured to be received by the rail 210 having a standardconfiguration. As shown in FIGS. 2 b and 2 c, the installer can continueto slide the clamp 200 into the rail 210. As shown in FIG. 2 d, once theclamp 200 has been slid a few centimeters into the rail 210, a module220 can be positioned on the rail 210. The process to secure the module220 to the rail 210 occurs similar to the method described above inFIGS. 1 a to 1 c, wherein the clamp 200 is tightened by bolt 200 a tosecure the module 220 to the rail 210. The bolt 200 a remains visibleand accessible to the installer, who can use a drill, screwdriver,pliers, wrench, or other tool to tighten the bolt 200 a of the clamp200. FIG. 2 e shows a perspective view of an installed clamp 200.

FIGS. 3 a and 3 b show a module end clamp 300 configured for securing amodule 310 to a side slot style rail 320. Similar to the module endclamp shown in FIGS. 1 a to 1 g, the module end clamp 300 has a body330, a nut 340, and a bolt 350. The body 330 has a horizontal component330 a and a vertical component 330 b extending perpendicular to thehorizontal component 330 a. At a distal end of the horizontal component330 a, the body 330 has a flange 330 c extending downwardly andperpendicular from the horizontal component 330 a. The verticalcomponent 330 b extends into a nut-receiving component 330 d thatextends outwardly in a direction away from the horizontal component 330a. In a direction parallel to the horizontal component 330 a, thenut-receiving component 330 d tapers to a point 330 e.

The bolt 350 extends through the nut 340 and into the body 330. The body330 has a threaded aperture for receiving a threaded component 350 a ofthe bolt 350. The bolt 350 can engage or disengage the nut 340 and thebody 330 by using torque to rotate a polygonal component 350 b at adistal end of the bolt 350. It is intended that the bolt 350 can haveany configuration at the distal end that allows a user to rotate thebolt or allows the bolt to engage or disengage, such as a screwdriverreceiving recess, and is not limited to a polygonal component, such as ahexagonal or pentagonal shaped component. In this exemplary embodiment,when the bolt 350 is completely tightened, a distal end of the threadedcomponent 350 a can extend past the nut-receiving component 330 d of thebody 330.

Because the rail 320 is configured differently than the rail shown inFIGS. 1 a to 1 d, the nut 340 can also be configured differently. Therail 320 has a first slot 320 a for receiving a bolt head, whereby abolt is used to secure the module 310 to the rail 320. The rail 320 hasa second slot 320 b for receiving a second bolt head for securing therail to a support on a surface. The body 330 of the clamp 300 has adownward extending flange that engages the first slot 320 a when thebolt 350 is tightened. The nut 340 has an aperture 340 a for receivingthe bolt 350. The nut 340 also has a nut flange 340 b that extends intothe second slot 320 b. A second nut flange 340 c extend from the nutflange 340 b toward a side of the second slot 320 b. When the bolt 350is tightened, the body 330 and the nut 340 engage each other as well asthe rail 320 to secure the module 310.

FIGS. 4 a to 4 c show a cross-sectional view of a grounding mid clamp400 secured to a grounding channel nut 410 according to an alternativeexemplary embodiment. The mid clamp 400 receives a bolt 420 that extendsfrom an upper end of the mid clamp 400, which is positioned above amodule 430, and past the other end of the module 430 through thegrounding channel nut 410. The grounding channel nut 410 can be securedin a rail 440 supporting the module 430. The mid clamp 400, bolt 420,and grounding channel nut 410 are preferably made from a conductivematerial that is harder than the module and rail materials (e.g.,aluminum) and does not rust or oxidize, such as stainless steel.

The mid clamp 400 has teeth 400 a that extend toward the module 430. Asthe bolt 420 is tightened, the teeth 400 a can puncture an anodizedaluminum module 430 to create an electrical ground path from the bolt420.

The grounding channel nut 410 has teeth 410 a extending in asubstantially upward direction. When the bolt 420 is tightened, thegrounding channel nut 410 moves in a direction closer to the mid clamp400. The teeth 410 a of the grounding channel nut 410 puncture the rail440 to create an electrical ground path in the rail 440. Stainless PEMinsert threads 450 can ensure electrical conductivity from the bolt 420to the grounding channel nut 410.

As shown in FIG. 4 a, the rail 440 runs in a direction substantiallyparallel to a seam between the two modules 430. However, the mid clamp400 can also be used in a configuration where the rail 440 runsperpendicular to the seam between the two modules, as shown in FIGS. 4 band 4 c. As further shown in FIG. 4 c, the mid clamp 400 can have asaw-toothed edge 400 b to grip the module 430. In one embodiment, theedge 400 b can puncture the anodized aluminum module 430.

The various embodiments of a clamp and the components thereof describedherein can be composed of any known or convenient material, including,but not limited to metal, fiberglass, plastic, wood, composites or anyother combination of materials. The clamp can be manufactured by anyprocess known in the art, including extrusion and cold-forging.

The embodiments described above are intended to be exemplary. Oneskilled in the art recognizes that numerous alternative components andembodiments that may be substituted for the particular examplesdescribed herein and still fall within the scope of the invention.

1. A clamp comprising: a bolt extending at least a width of a module; abody having: an aperture to receive the bolt; and a body flangeextending from the body toward the module; and a nut having: a nutaperture for receiving the bolt; and a first nut flange and a second nutflange extending from the module; wherein tightening of the bolt causesthe nut and the body to secure the module and rail together, wherein thebody flange is configured to pierce the module, and wherein the firstnut flange and the second nut flange are configured to pierce the rail.2. The clamp according to claim 1, wherein the body and the nut are madeof a material harder than the material of the module and the rail.